Methods for shaping an extrudable material

ABSTRACT

An apparatus for shaping an extrudable material comprises a sleeve, comprising a first sleeve end, a sleeve inlet at the first sleeve end, a second sleeve end, opposite the first sleeve end, and a sleeve outlet at the second sleeve end. The extrudable material enters the sleeve through the sleeve inlet and exits the sleeve through the sleeve outlet. The apparatus further comprises an actuation mechanism, selectively operable to change at least one of a size or a shape of the sleeve outlet. The sleeve is sufficiently flexible to enable the actuation mechanism to change at least one of the size or the shape of the sleeve outlet. The sleeve is insufficiently stretchable to enable the actuation mechanism to stretch the sleeve.

TECHNICAL FIELD

The present disclosure relates to apparatuses and methods for shaping anextrudable material delivered to a workpiece.

BACKGROUND

It is commonplace to use extrusion tools, e.g., nozzles, for deliveringextrudable materials, such as 3D-printing materials or sealants, to aworkpiece. The shape of the extrudate delivered from each extrusion toolis fixed. Accordingly, to change the shape of the extrudate, deliveredto the workpiece, one extrusion tool must be replaced with anotherduring the extrusion cycle, negatively impacting design freedom andincreasing manufacturing cycle time.

SUMMARY

Accordingly, apparatuses and methods, intended to address at least theabove-identified concerns, would find utility.

The following is a non-exhaustive list of examples, which may or may notbe claimed, of the subject matter according to the invention.

One example of the subject matter according to the invention relates toan apparatus for shaping an extrudable material. The apparatus comprisesa sleeve. The sleeve comprises a first sleeve end, a sleeve inlet at thefirst sleeve end, a second sleeve end, opposite the first sleeve end,and a sleeve outlet at the second sleeve end. The extrudable materialenters the sleeve through the sleeve inlet and exits the sleeve throughthe sleeve outlet. The apparatus further comprises an actuationmechanism, selectively operable to change at least one of a size or ashape of the sleeve outlet. The sleeve is sufficiently flexible toenable the actuation mechanism to change at least one of the size or theshape of the sleeve outlet. The sleeve is insufficiently stretchable toenable the actuation mechanism to stretch the sleeve.

Use of sleeve and actuation mechanism provide adjustment to the sizeand/or shape of extrudable material exiting sleeve outlet during amanufacturing process, such as an additive manufacturing method. Theability to adjust the size and/or shape of extrudable material from asingle apparatus facilitates the formation of self-supporting,out-of-plane structures using additive manufacturing methods without theneed to substitute one apparatus (e.g., nozzle) for another. In otherwords, selective operation of actuation mechanism to change the sizeand/or the shape of sleeve outlet facilitates on-the-fly changes to thesize and/or the shape of extrudable material extruded from sleeve outletin an additive manufacturing process. Additionally, use of sleeve andactuation mechanism allows additive manufacturing processes to formparts with higher material throughput, reduced material usage, improvedinterlaminar adhesion, faster print speeds, better part geometry, bettersurface control, and reduced post-processing steps. Furthermore, sleeve,being both flexible and non-stretchable, promotes changes to the sizeand/or the shape of extrudable material, while not allowing the pressureof extrudable material to deform sleeve, which facilitates predictableand controllable flow rates of extrudable material from sleeve.

Another example of the subject matter according to the invention relatesto a method of shaping an extrudable material. The method comprisesadvancing the extrudable material through a sleeve that comprises asecond sleeve end and sleeve outlet at the second sleeve end. The methodfurther comprises selectively changing at least one of a size or a shapeof the sleeve outlet.

The ability to selectively change the size and/or the shape of sleeveoutlet facilitates adjustment of the size and/or shape of extrudablematerial delivered from a single apparatus, which promotes the formationof self-supporting, out-of-plane structures using additive manufacturingmethods without the need to substitute one nozzle for another. In otherwords, selective changing of the size and/or the shape of sleeve outletfacilitates on-the-fly changes to the size and/or the shape ofextrudable material extruded from sleeve outlet in an additivemanufacturing process. Additionally, selectively changing at least oneof the size or the shape of sleeve outlet allows additive manufacturingprocesses to form parts with higher material throughput, reducedmaterial usage, improved interlaminar adhesion, faster print speeds,better part geometry, better surface control, and reducedpost-processing steps. Furthermore, sleeve, being both flexible andnon-stretchable, promotes changes to the size and/or the shape ofextrudable material, while not allowing the pressure of extrudablematerial to deform sleeve, which facilitates predictable andcontrollable flow rates of extrudable material from sleeve.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described one or more examples of the invention in generalterms, reference will now be made to the accompanying drawings, whichare not necessarily drawn to scale, and wherein like referencecharacters designate the same or similar parts throughout the severalviews, and wherein:

FIG. 1 is a block diagram of a system for shaping an extrudablematerial, according to one or more examples of the present disclosure;

FIG. 2 is a schematic, top perspective view of an apparatus of thesystem of FIG. 1 , according to one or more examples of the presentdisclosure;

FIG. 3 is a schematic, bottom perspective view of the apparatus of FIG.2 , according to one or more examples of the present disclosure;

FIG. 4 is a schematic, end view of the apparatus of FIG. 2 , accordingto one or more examples of the present disclosure;

FIG. 5 is a schematic, cross-sectional view of the apparatus of FIG. 2 ,according to one or more examples of the present disclosure;

FIG. 6 is a schematic, end view of the apparatus of FIG. 2 , accordingto one or more examples of the present disclosure;

FIG. 7 is a schematic, end view of the apparatus of FIG. 2 , accordingto one or more examples of the present disclosure;

FIG. 8 is a schematic, end view of an apparatus of the system of FIG. 1, according to one or more examples of the present disclosure;

FIG. 9 is a schematic, cross-sectional view of the apparatus of FIG. 8 ,according to one or more examples of the present disclosure;

FIG. 10 is a schematic, side view of a sleeve of the system of FIG. 1 ,according to one or more examples of the present disclosure;

FIG. 11 is a schematic, side view of a sleeve of the system of FIG. 1 ,according to one or more examples of the present disclosure;

FIG. 12 is a schematic, side view of a sleeve of the system of FIG. 1 ,according to one or more examples of the present disclosure;

FIG. 13 is a schematic, side view of a sleeve of the system of FIG. 1 ,according to one or more examples of the present disclosure;

FIG. 14 is a schematic, end view of an apparatus of the system of FIG. 1, according to one or more examples of the present disclosure;

FIG. 15 is a schematic, cross-sectional view of an apparatus of thesystem of FIG. 1 , according to one or more examples of the presentdisclosure;

FIG. 16 is a schematic, cross-sectional view of an apparatus of thesystem of FIG. 1 , according to one or more examples of the presentdisclosure;

FIG. 17 is a schematic, cross-sectional view of an apparatus of thesystem of FIG. 1 , according to one or more examples of the presentdisclosure;

FIG. 18(a) is a schematic, end view of a sleeve and a shaping ring of anapparatus of the system of FIG. 1 in a first shaped configuration,according to one or more examples of the present disclosure;

FIG. 18(b) is a schematic, end view of a sleeve and a shaping ring of anapparatus of the system of FIG. 1 in a second shaped configuration,according to one or more examples of the present disclosure;

FIG. 18(c) is a schematic, end view of a sleeve and a shaping ring of anapparatus of the system of FIG. 1 in a third shaped configuration,according to one or more examples of the present disclosure;

FIG. 19 is a block diagram of a method of shaping an extrudablematerial, according to one or more examples of the present disclosure;

FIG. 20 is a block diagram of aircraft production and servicemethodology; and

FIG. 21 is a schematic illustration of an aircraft.

DETAILED DESCRIPTION

In FIG. 1 , referred to above, solid lines, if any, connecting variouselements and/or components may represent mechanical, electrical, fluid,optical, electromagnetic and other couplings and/or combinationsthereof. As used herein, “coupled” means associated directly as well asindirectly. For example, a member A may be directly associated with amember B, or may be indirectly associated therewith, e.g., via anothermember C. It will be understood that not all relationships among thevarious disclosed elements are necessarily represented. Accordingly,couplings other than those depicted in the block diagrams may alsoexist. Dashed lines, if any, connecting blocks designating the variouselements and/or components represent couplings similar in function andpurpose to those represented by solid lines; however, couplingsrepresented by the dashed lines may either be selectively provided ormay relate to alternative examples of the present disclosure. Likewise,elements and/or components, if any, represented with dashed lines,indicate alternative examples of the present disclosure. One or moreelements shown in solid and/or dashed lines may be omitted from aparticular example without departing from the scope of the presentdisclosure. Environmental elements, if any, are represented with dottedlines. Virtual (imaginary) elements may also be shown for clarity. Thoseskilled in the art will appreciate that some of the features illustratedin FIG. 1 may be combined in various ways without the need to includeother features described in FIG. 1 , other drawing figures, and/or theaccompanying disclosure, even though such combination or combinationsare not explicitly illustrated herein. Similarly, additional featuresnot limited to the examples presented, may be combined with some or allof the features shown and described herein.

In FIG. 19 , referred to above, the blocks may represent operationsand/or portions thereof and lines connecting the various blocks do notimply any particular order or dependency of the operations or portionsthereof. Blocks represented by dashed lines indicate alternativeoperations and/or portions thereof. Dashed lines, if any, connecting thevarious blocks represent alternative dependencies of the operations orportions thereof. It will be understood that not all dependencies amongthe various disclosed operations are necessarily represented. FIG. 19and the accompanying disclosure describing the operations of themethod(s) set forth herein should not be interpreted as necessarilydetermining a sequence in which the operations are to be performed.Rather, although one illustrative order is indicated, it is to beunderstood that the sequence of the operations may be modified whenappropriate. Accordingly, certain operations may be performed in adifferent order or simultaneously. Additionally, those skilled in theart will appreciate that not all operations described need be performed.

In the following description, numerous specific details are set forth toprovide a thorough understanding of the disclosed concepts, which may bepracticed without some or all of these particulars. In other instances,details of known devices and/or processes have been omitted to avoidunnecessarily obscuring the disclosure. While some concepts will bedescribed in conjunction with specific examples, it will be understoodthat these examples are not intended to be limiting.

Unless otherwise indicated, the terms “first,” “second,” etc. are usedherein merely as labels, and are not intended to impose ordinal,positional, or hierarchical requirements on the items to which theseterms refer. Moreover, reference to, e.g., a “second” item does notrequire or preclude the existence of, e.g., a “first” or lower-numbereditem, and/or, e.g., a “third” or higher-numbered item.

Reference herein to “one example” means that one or more feature,structure, or characteristic described in connection with the example isincluded in at least one implementation. The phrase “one example” invarious places in the specification may or may not be referring to thesame example.

As used herein, a system, apparatus, structure, article, element,component, or hardware “configured to” perform a specified function isindeed capable of performing the specified function without anyalteration, rather than merely having potential to perform the specifiedfunction after further modification. In other words, the system,apparatus, structure, article, element, component, or hardware“configured to” perform a specified function is specifically selected,created, implemented, utilized, programmed, and/or designed for thepurpose of performing the specified function. As used herein,“configured to” denotes existing characteristics of a system, apparatus,structure, article, element, component, or hardware which enable thesystem, apparatus, structure, article, element, component, or hardwareto perform the specified function without further modification. Forpurposes of this disclosure, a system, apparatus, structure, article,element, component, or hardware described as being “configured to”perform a particular function may additionally or alternatively bedescribed as being “adapted to” and/or as being “operative to” performthat function.

Illustrative, non-exhaustive examples, which may or may not be claimed,of the subject matter according the present disclosure are providedbelow.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2-9 and14-17 , apparatus 110 for shaping extrudable material 140 is disclosed.Apparatus 110 comprises sleeve 126, comprising first sleeve end 186,sleeve inlet 148 at first sleeve end 186, second sleeve end 188,opposite first sleeve end 186, and sleeve outlet 132 at second sleeveend 188. Extrudable material 140 enters sleeve 126 through sleeve inlet148 and exits sleeve 126 through sleeve outlet 132. Apparatus 110further comprises actuation mechanism 172, selectively operable tochange at least one of a size or a shape of sleeve outlet 132. Sleeve126 is sufficiently flexible to enable actuation mechanism 172 to changeat least one of the size or the shape of sleeve outlet 132. Sleeve 126is insufficiently stretchable to enable actuation mechanism 172 tostretch sleeve 126. The preceding subject matter of this paragraphcharacterizes example 1 of the present disclosure.

Use of sleeve 126 and actuation mechanism 172 provide adjustment to thesize and/or shape of extrudable material 140 exiting sleeve outlet 132,and delivered to workpiece 170, during a manufacturing process, such asan additive manufacturing method. The ability to adjust the size and/orshape of extrudable material 140 from a single apparatus facilitates theformation of self-supporting, out-of-plane structures using additivemanufacturing methods without the need to substitute one apparatus(e.g., nozzle) for another. In other words, selective operation ofactuation mechanism 172 to change the size and/or the shape of sleeveoutlet 132 facilitates on-the-fly changes to the size and/or the shapeof extrudable material 140 extruded from sleeve outlet 132 in anadditive manufacturing process. Additionally, use of sleeve 126 andactuation mechanism 172 allows additive manufacturing processes to formparts with higher material throughput, reduced material usage, improvedinterlaminar adhesion, faster print speeds, better part geometry, bettersurface control, and reduced post-processing steps. Furthermore, sleeve126, being both flexible and non-stretchable, promotes changes to thesize and/or the shape of extrudable material 140, while not allowing thepressure of extrudable material 140 to deform sleeve 126, whichfacilitates predictable and controllable flow rates of extrudablematerial 140 from sleeve 126.

Sleeve 126 is more flexible than support structure 115 and feed tube112. In this manner, sleeve 126 can flex relative to support structure115 and feed tube 112. In one example, sleeve 126 comprises a tubularmesh sleeve and a membrane, through which extrudable material 140 isimpenetrable, impregnated in or lining the tubular mesh sleeve. Thetubular mesh sleeve comprises an interlocking network of rigid links insome examples or braided fibers in other examples. The rigid links aremade of a metal, hardened plastic, carbon fibers, or other materialsthat do not stretch under the pressure of extrudable material 140advancing through sleeve 126. The membrane is made from a rubber, orother similar material, that alone is stretchable, but when coupled withthe tubular mesh sleeve is not stretchable.

Extrudable material 140 is made of any of various materials capable ofbeing extruded through sleeve 126. In one example, extrudable material140 is made of one or more of melted plastic, resin, sealant, adhesive,or the like.

In one example, actuation mechanism 172 is selectively operable viacontroller 102, which can be an electronic controller, programmed tocontrol operation of system 100, including actuation mechanism 172.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2-9 and14-16 , actuation mechanism 172 further comprises plurality of actuators122. Actuation mechanism also comprises plurality of cables 128,surrounding sleeve 126. Each one of plurality of cables 128 comprisesfirst cable end 180, coupled to a corresponding one of plurality ofactuators 122, and second cable end 182, opposite first cable end 180,co-movably coupled to second sleeve end 188 of sleeve 126. Each one ofplurality of actuators 122 is selectively operable to pull or push acorresponding one of plurality of cables 128 to change at least one ofthe size or the shape of sleeve outlet 132 of sleeve 126. The precedingsubject matter of this paragraph characterizes example 2 of the presentdisclosure, wherein example 2 also includes the subject matter accordingto example 1, above.

Plurality of cables 128 promotes a simple and reliable actuation methodfor changing the size and/or the shape of sleeve outlet 132.Additionally, because plurality of cables 128 can be flexible andcross-sectionally small, plurality of cables 128 promote flexibility inthe placement and orientation of plurality of cables 128, which allowsplurality of actuators 122 to be positioned away from sleeve outlet 132if desired. Plurality of actuators 122 promote automated changing of atleast one of the size or the shape of sleeve outlet 132. Furthermore,plurality of actuators 122 facilitate precise and predictable control ofat least one of the size or the shape of sleeve outlet 132. Plurality ofactuators 122 and plurality of cables 128 improves the adjustability ofthe size and/or the shape of sleeve outlet 132. Each one of plurality ofcables 128 adjusts a localized portion of sleeve outlet 132, whichresults in a localized change in the size and/or the shape of sleeveoutlet 132. The collective localized changes in the size and/or theshape of sleeve outlet 132 results in an overall change in the sizeand/or the shape of sleeve outlet 132. The higher the number ofplurality of cables 128, the greater the customization of the sizeand/or the shape of sleeve outlet 132 in some examples.

Each one of plurality of actuators 122 comprises a motor, in oneexample. The motor is selectively operable to extend (e.g., push) andretract (e.g., pull) a corresponding one of plurality of cables 128.According to one example, the motor operates as a winch. The motor is anelectric motor, pneumatic motor, hydraulic motor, electromagnetic motor,or other similar motor. According to other examples, each one ofplurality of actuators 122 comprises one or more of solenoids,piezo-electric actuators, screw-type linear actuators, and the like.

According to one example, each one of plurality of cables 128 is capableof being pushed without buckling and/or pulled without stretching. Inone example, each one of plurality of cables 128 is made of a metal,such as stainless steel. Furthermore, in an example, each one ofplurality of cables 128 is a thin, narrow strip of spring steel.

Referring to FIG. 15 , in one example, plurality of actuators 122 ismounted to support tube 116 within cavity 124 of support tube 116.Furthermore, in such an example, each one of plurality of cables 128 canbe a straight, non-flexible, rod. In other examples, plurality ofactuators 122 is mounted to support tube 116 on exterior surface ofsupport tube 116, opposite cavity 124, such that plurality of cables 128passes through support tube 116.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2-9, 14,and 16 , apparatus 110 further comprises support structure 115.Actuation mechanism 172 further comprises plurality of cable tubes 118,fixed to support structure 115. Each one of plurality of cables 128passes through a corresponding one of plurality of cable tubes 118 froma corresponding one of plurality of actuators 122 to second sleeve end188 of sleeve 126. Support structure 115 is more rigid than sleeve 126.The preceding subject matter of this paragraph characterizes example 3of the present disclosure, wherein example 3 also includes the subjectmatter according to example 2, above.

Plurality of cable tubes 118 help to protect, guide, and prevent bindingof plurality of cables 128 as they are pulled or pushed by plurality ofactuators 122. Support structure 115 provides a relatively rigidframework to fix plurality of actuators 122 and plurality of cable tubes118 relative to sleeve 126.

Each one of plurality of cable tubes 118 is longitudinallyincompressible. For example, each one of plurality of cables 128 andeach corresponding one of plurality of cable tubes 118 cooperativelyform a so-called Bowden cable. Accordingly, in one example, each one ofplurality of cable tubes comprises a housing with an inner lining, ahelical winding or sheaf of metal wire, and an outer covering. In someexamples, plurality of cable tubes 118 is as rigid as support structure115.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2-9, 14,and 16 , each one of plurality of cable tubes 118 of actuation mechanism172 is more rigid than the corresponding one of plurality of cables 128of actuation mechanism 172. The preceding subject matter of thisparagraph characterizes example 4 of the present disclosure, whereinexample 4 also includes the subject matter according to example 3,above.

Plurality of cable tubes 118, being more rigid than plurality of cables128, provide structure that help to retain plurality of cables 128 in adesignated push/pull path.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2-9, 14,and 16 , support structure 115 comprises support tube 116, definingcavity 124. Sleeve 126 is within cavity 124 of support tube 116. Supporttube 116 supports plurality of cable tubes 118. The preceding subjectmatter of this paragraph characterizes example 5 of the presentdisclosure, wherein example 5 also includes the subject matter accordingto example 3 or 4, above.

Support tube 116 provides a rigid framework to support plurality ofcable tubes 118 relative to sleeve 126. Moreover, support tube 116 helpsprotect sleeve 126 from impacts by external objects.

As shown in FIG. 16 , according to one example, actuation mechanism 172further comprises plurality of springs 169, between second sleeve end188 of sleeve 126 and support tube 116. Plurality of springs 169 biasessecond sleeve end 188 toward or away from support tube 116. In oneexample, each one of plurality of springs 169 is a pull spring thatbiases second sleeve end 188 toward support tube 116 and each one ofplurality of cables 128 is a push cable that is pushed by acorresponding one of plurality of actuators 122 to move second sleeveend 188 of sleeve 126 away from support tube 116 against bias of acorresponding one of plurality of springs 169. In another example, eachone of plurality of springs 169 is a push spring that biases secondsleeve end 188 away from support tube 116 and each one of plurality ofcables 128 is a pull cable that is pulled by a corresponding one ofplurality of actuators 122 to move second sleeve end 188 of sleeve 126toward support tube 116 against bias of a corresponding one of pluralityof springs 169. In one example, each one of plurality of springs 169 isa coil spring and second cable end 182 of each one of plurality ofcables 128 can be concentric with a corresponding one of plurality ofsprings 169.

As shown in FIG. 17 , according to one example, actuation mechanism 172comprises plurality of actuators 122 and plurality of first rods 171,each movable by a corresponding one of plurality of actuators 122.Actuation mechanism 172 also comprises plurality of rocker arms 175,each pivotably coupled to support tube 116 and each movable by acorresponding one of plurality of first rods 171. Actuation mechanism172 additionally comprises plurality of second rods 173, each movable bya corresponding one of plurality of rocker arms 175 and each coupled tosecond sleeve end 188 of sleeve 126. Plurality of rockers 175 pivot infirst rotational direction to facilitate movement of second sleeve end188 of sleeve 126 toward support tube 116, and pivot in secondrotational direction, opposite first rotational direction, to facilitatemovement of second sleeve end 188 of sleeve 126 away from support tube116. In one example, each one of plurality of first rods 172 ispivotably coupled to a corresponding one of plurality of rocker arms 175by a pin. Similarly, in an example, each one of plurality of second rods173 is pivotably coupled to a corresponding one of plurality of rockerarms 175 by a pin. Alternatively, in yet another example, plurality offirst rods 172 and plurality of second rods 173 merely rest against acorresponding one of plurality of rocker arms 175, and actuationmechanism 172 further comprises plurality of springs, each interposedbetween support tube 116 and a corresponding one of plurality of rockerarms 175 and each biasing the corresponding one of plurality of rockerarms 175 in the second rotational direction.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2-9, 14,and 16 , support structure 115 comprises support ring 114. Support ring114 supports plurality of actuators 122. The preceding subject matter ofthis paragraph characterizes example 6 of the present disclosure,wherein example 6 also includes the subject matter according to any oneof examples 3 to 5, above.

Support ring 114 provides a rigid framework to support plurality ofactuators 122 relative to sleeve 126. In some examples, support ring 114also provides a rigid framework to help support plurality of cable tubes118 relative to sleeve 126.

In one example, support tube 116 is fixed to and extends from supportring 114. Plurality of actuators 122 is fixed to an exterior surface ofsupport ring 114. Plurality of cables 128 passes from plurality ofactuators 122, through support ring 114, along exterior surface ofsupport tube 116, and through support tube 116 before coupling to secondsleeve end 188 of sleeve 126. Plurality of cable tubes 118 passes fromsupport ring 114, along exterior surface of support tube 116, andthrough support tube 116 in some examples. According to one example,support ring 114 is coupled to first sleeve end 186 of sleeve 126 andplurality of cable tubes 118 passes through support tube 116 laterallyadjacent second sleeve end 188 of sleeve 126.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2-9 and14-17 , apparatus 110 further comprises feed tube 112, comprising tubeinlet 120 and tube outlet 142, opposite tube inlet 120. Supportstructure 115 is spatially fixed relative to feed tube 112. Sleeve 126is sealingly coupled to feed tube 112 so that sleeve inlet 148 is incommunication with tube outlet 142. Feed tube 112 is more rigid thansleeve 126. The preceding subject matter of this paragraph characterizesexample 7 of the present disclosure, wherein example 7 also includes thesubject matter according to any one of examples 3 to 6, above.

Feed tube 112 provides a rigid framework for anchoring sleeve 126.Additionally, feed tube 112 receives extrudable material 140 from amaterial source and delivers extrudable material 140 to sleeve 126.Also, feed tube 112 may facilitate attachment of apparatus 110 to asystem actuator configured to move apparatus 110 into materialdispensing positions for dispensing extrudable material 140 from sleeveoutlet 132 during an additive manufacturing process.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 5, 9, and15 , apparatus 110 further comprises compression clamp 144, coupled tosleeve 126 such that a portion of first sleeve end 186 of sleeve 126 isinterposed between compression clamp 144 and feed tube 112 and theportion of first sleeve end 186 of sleeve 126 is compressed betweencompression clamp 144 and feed tube 112. The preceding subject matter ofthis paragraph characterizes example 8 of the present disclosure,wherein example 8 also includes the subject matter according to example7, above.

Compression clamp 144 helps form a seal between sleeve 126 and feed tube112 to prevent leakage of extrudable material 140 out from within tubechannel 150 and sleeve channel 152.

In one example, compression clamp 144 comprises a band, with notches,and a captive screw that engages the notches as the captive screwrotates to tighten or loosen the band. According to an example,compression clamp 144 is a conventional hose clamp. In other examples,compression clamp 144 comprises any of various other devices, such as acable tie, rubber band, etc., capable of compressing the portion offirst sleeve end 186 against feed tube 112.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2-9 and14-16 , extrudable material 140 advances through sleeve 126 in flowdirection 184. At least a portion of second cable end 182 of each one ofplurality of cables 128 is perpendicular to flow direction 184 ofextrudable material 140. The preceding subject matter of this paragraphcharacterizes example 9 of the present disclosure, wherein example 9also includes the subject matter according to any one of examples 2 to10, above.

At least a portion of second cable end 182 of each one of plurality ofcables 128, being perpendicular to flow direction 184 promotes movement(e.g., flexing) of a portion of sleeve outlet 132 in directionperpendicular to flow direction 184, which facilitates a change in atleast one of the size or the shape of sleeve outlet 132.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2-9, 14,and 16 , at least a portion of first cable end 180 of each one ofplurality of cables 128 is parallel to flow direction 184 of extrudablematerial 140. The preceding subject matter of this paragraphcharacterizes example 10 of the present disclosure, wherein example 10also includes the subject matter according to example 9, above.

At least a portion of first cable end 180 of each one of plurality ofcables 128, being parallel to flow direction 184 allows first cable end180 of each one of plurality of cables 128 and plurality of actuators122 to be located away from sleeve outlet 132 while promoting a narrowfootprint of apparatus 110.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2-9, 14,and 15 , in a plane perpendicular to flow direction 184 of extrudablematerial 140, second cable end 182 of each one of plurality of cables128 is equidistant from second cable end 182 of first directly adjacentone of plurality of cables 128 and second cable end 182 of seconddirectly adjacent one of plurality of cables 128. The preceding subjectmatter of this paragraph characterizes example 11 of the presentdisclosure, wherein example 11 also includes the subject matteraccording to example 9 or 10, above.

Second cable end 182 of each one of plurality of cables 128, beingequidistant from second cable end 182 of a first directly adjacent oneof plurality of cables 128 and second cable end 182 of a second directlyadjacent one of plurality of cables 128 in a plane perpendicular to flowdirection 184 of extrudable material 140, helps promote symmetricalchanges to the size and/or the shape of sleeve outlet 132 if desired.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 2-9, 14,and 15 , first one of plurality of actuators 122 is selectively operableto pull first one of plurality of cables 128. Second one of plurality ofactuators 122 is selectively operable to push second one of plurality ofcables 128. The preceding subject matter of this paragraph characterizesexample 12 of the present disclosure, wherein example 12 also includesthe subject matter according to any one of examples 2 to 11, above.

Pulling one of plurality of cables 128 while pushing another one ofplurality of cables 128 promotes the customization of the size and/orthe shape of sleeve outlet 132.

In one example, as shown in FIG. 6 , some of plurality of cables 128 arepushed in first direction 190 and others of plurality of cables 128 arepulled in second direction 192. According to some examples, actuationmechanism 172 is selectively operable to reverse direction of cables sothat the one or more of plurality of cables 128 being pushed in firstdirection 190 are pulled in second direction 192 and one or more ofplurality of cables 128 being pulled in second direction 192 are pushedin first direction 190.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 3-7 and15 , actuation mechanism 172 further comprises shaping ring 130,surrounding sleeve 126 and coupled to second sleeve end 188 of sleeve126. Shaping ring 130 is adjustable to change at least one of the sizeor the shape of sleeve outlet 132. The preceding subject matter of thisparagraph characterizes example 13 of the present disclosure, whereinexample 13 also includes the subject matter according to any one ofexamples 2 to 12, above.

Shaping ring 130 facilitates a change of the size and/or the shape ofsleeve outlet 132 by providing a rigid, yet rearrangeable, framework tosleeve outlet 132. For example, shaping ring 130 maintains the sizeand/or the shape of sleeve outlet 132 while extrudable material 140 isadvanced through sleeve outlet 132.

Shaping ring 130 is more rigid than sleeve 126. In one example, shapingring 130 is sufficiently adjustable to enable actuation mechanism 172 tochange at least one of the size or the shape of sleeve outlet 132 andsufficiently rigid to retain its shape as extrudable material 140advances through sleeve outlet 132.

In one example, second cable end 182 of each one of plurality of cables128 is co-movably coupled to second sleeve end 188 of sleeve 126 viashaping ring 130. More specifically, second cable end 182 of each one ofplurality of cables 128 is directly coupled to shaping ring 130 andshaping ring 130 is directly coupled to second sleeve end 188 of sleeve126 such that shaping ring 130 is interposed between second cable end182 of each one of plurality of cables 128 and second sleeve end 188 ofsleeve 126.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 3-7 and15 , the size and the shape of sleeve outlet 132 correspond to a sizeand a shape, respectively, of shaping ring 130. The preceding subjectmatter of this paragraph characterizes example 14 of the presentdisclosure, wherein example 14 also includes the subject matteraccording to example 13, above.

The size and the shape of shaping ring 130 corresponding with the sizeand the shape of sleeve outlet 132 allows a desirable size and/or theshape of sleeve outlet 132 to be achieved by changing shaping ring 130into the same desirable size and/or shape. Also, because shaping ring130 acts as a barrier to prevent outward flexing of sleeve outlet 132away from central axis 194, the size and the shape of shaping ring 130corresponding with the size and the shape of sleeve outlet 132 helpsensure the size and/or the shape of sleeve outlet 132 is maintainedwhile extrudable material 140 is advanced through sleeve outlet 132.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 3-7 and15 , shaping ring 130 comprises at least four links 134. Shaping ring130 also comprises at least four pivot couplers 136, each pivotallycoupling together two of at least four links 134. Each of at least fourlinks 134 is more rigid than sleeve 126. The preceding subject matter ofthis paragraph characterizes example 15 of the present disclosure,wherein example 15 also includes the subject matter according to example13 or 14, above.

At least four links 134 of shaping ring 130 enables sleeve outlet 132 tohave a shape with at least four sides. Furthermore, at least four links134, being more rigid than sleeve 126, provide a rigid frameworkpreventing sleeve outlet 132 from further flexing. Additionally, atleast four links 134 facilitate reshaping or resizing of sleeve outlet132 as shaping ring 130 is reshaped or resized. Each of at least fourpivot couplers 136 facilitates pivoting motion between two adjacent onesof four links 134. Moreover, at least four pivot couplers 136 allow anytwo adjacent links 134 to be pivotably movable relative to each otherindependently of the pivoting motion of any other two adjacent ones offour links 134.

In one example, each of four links 134 comprises two knuckle portions atopposing ends of each of four links 134. Each one of the two knuckleportions of each of four links 134 interlocks with a corresponding oneof the two knuckle portions of an adjacent one of four links 134. Eachof at least four pivot couplers 136 comprises a pin that passes througha corresponding one of four interlocking knuckle portions. According toone example, each one of the four interlocking knuckle portions andcorresponding pin is configured like a conventional door hinge. Adjacentones of four links 134 are able to pivot about the pivot couplers whenactuated by actuation mechanism 172.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 3-7 and15 , second cable end 182 of each one of plurality of cables 128 isco-movably coupled to a corresponding one of at least four pivotcouplers 136. The preceding subject matter of this paragraphcharacterizes example 16 of the present disclosure, wherein example 16also includes the subject matter according to example 15, above.

Plurality of actuators 122 and plurality of cables 128 facilitateautomated movement of at least four pivot couplers 136, toward and awayfrom central axis 194, independently of each other. Independent motionof at least four pivot couplers 136 in this manner promotescustomization of the size and/or the shape of sleeve outlet 132.

In one example, second cable end 182 of each one of plurality of cablesis co-movably coupled to a corresponding one of at least four pivotcouplers 136 with a fastener, weldment, bracket, and/or other similarcoupler.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 3-7 and15 , actuators in plurality of actuators 122 and links in at least fourlinks 134 are equal in number. Cables in plurality of cables 128 andlinks in at least four links 134 are equal in number. The precedingsubject matter of this paragraph characterizes example 17 of the presentdisclosure, wherein example 17 also includes the subject matteraccording to example 16, above.

Having actuators in plurality of actuators 122 and links in at leastfour links 134 being equal in number, and cables in plurality of cables128 and links in at least four links 134 being equal, facilitatecustomization of the size and/or the shape of shaping ring 130 with anygiven quantity of links.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 3-9, 14,and 15 , actuation mechanism 172 is further selectively operable tochange the shape of sleeve outlet 132 from one polygonal shape to anyone of a plurality of other polygonal shapes. The preceding subjectmatter of this paragraph characterizes example 18 of the presentdisclosure, wherein example 18 also includes the subject matteraccording to any one of examples 1 to 17, above.

Actuation mechanism 172, being selectively operable to change the shapeof sleeve outlet 132 from one polygonal shape to any one of a pluralityof other polygonal shapes, allows a structure to be formed withextrudable material 140 having multiple polygonal shapes using anadditive manufacturing process.

In one example, shape of sleeve outlet 132 is octagonal in FIG. 4 ,square in FIG. 6 , and a four-point star in FIG. 7 . Actuation mechanism172 is selectively operable to alternatingly pull in first direction 190and push in second direction 192 adjacent ones of at least four pivotcouplers 136 to change the shape of sleeve outlet 132 from octagonal inFIG. 4 to square in FIG. 6 . Actuation mechanism 172 is furtherselectively operable to alternatingly pull in first direction 190 andpush in second direction 192 adjacent ones of at least four pivotcouplers 136 to change the shape of sleeve outlet 132 from square inFIG. 6 to four-point start in FIG. 7 .

According to one example, shape of sleeve outlet 132 is an L-shape inFIG. 18(a), a C-shape in FIG. 18(b), and an I-shape in FIG. 18(c). Thevariety of shapes of sleeve outlet 132, such as those shown in FIG. 18 ,facilitated by apparatus 110 promotes extrudate with a higherself-supporting and stiffer structure compared to conventionalextrudate, which allows for out-of-plane additive manufacturing.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 3-9, 14,and 15 , the one polygonal shape has a first number of sides. At leastone of the plurality of other polygonal shapes has a second number ofsides different than the first number of sides of the one polygonalshape. The preceding subject matter of this paragraph characterizesexample 19 of the present disclosure, wherein example 19 also includesthe subject matter according to example 18, above.

At least one of the plurality of other polygonal shapes having a secondnumber of sides different than the first number of sides of the onepolygonal shape allows a structure to be formed with extrudable material140 having fundamentally different polygonal shapes using an additivemanufacturing process.

As an example, the octagonal shape of sleeve outlet 132 in FIG. 4 haseight sides and the square shape of sleeve outlet 132 in FIG. 6 has foursides.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 8-13 ,sleeve 126 has a thickness and comprises plurality of grooves 162.Sleeve 126 further comprises plurality of sleeve segments 160. Adjacentones of plurality of sleeve segments 160 are interconnected by acorresponding one of plurality of grooves 162. The thickness of sleeve126 at each one of plurality of grooves 162 is less than the thicknessof sleeve 126 at each one of plurality of sleeve segments 160. Sleeve126 is more flexible along any one of plurality of grooves 162 thanacross any one of plurality of sleeve segments 160. The precedingsubject matter of this paragraph characterizes example 20 of the presentdisclosure, wherein example 20 also includes the subject matteraccording to any one of examples 1 to 19, above.

Plurality of grooves 162 provide corresponding regions of reducedthickness of sleeve 126. The regions of reduced thickness promoteflexibility, which allows adjacent ones of plurality of sleeve segments160 to pivot relative to each other to change the size and/or the shapeof sleeve outlet 132. Plurality of sleeve segments 160, being thickerthan plurality of grooves 162, and thus less flexible than regions ofreduced thickness provided by plurality of grooves 162, provide a strongframework for resisting deformation due to the pressure of extrudablematerial 140 as extrudable material 140 flows through sleeve 126.

A thickness of sleeve 126 is less along plurality of grooves 162 thanalong plurality of sleeve segments 160. In one example, a material ofsleeve 126 is the same along plurality of grooves 162 and plurality ofsleeve segments 160. The material of sleeve 126 along plurality ofgrooves 162 and plurality of sleeve segments 160 comprises non-porousmaterials, such as metal, plastic, and/or fiber-reinforced polymers, insome examples. For sleeve 126 made of a fiber-reinforced polymer alongplurality of grooves 162, fibers are parallel to plurality of grooves162.

According to one example, as shown in FIG. 13 , actuation mechanism 172of apparatus 110 does not have shaping ring 130 and sleeve 126 does nothave plurality of grooves 162. In such an example, second cable end 182of each one of plurality of cables 128 is coupled directly to sleeve126.

Referring generally to FIG. 1 and particularly to, e.g., FIGS. 8 and 9 ,none of plurality of grooves 162 intersects any other one of pluralityof grooves 162. The preceding subject matter of this paragraphcharacterizes example 21 of the present disclosure, wherein example 21also includes the subject matter according to example 20, above.

Having none of plurality of grooves 162 intersect any other one ofplurality of grooves 162 allows a shape of sleeve channel 152 of sleeve126, at a location along central axis 194 of sleeve channel 152 awayfrom sleeve outlet 132, to be substantially the same as at the sleeveoutlet 132. Maintaining a constant shape along sleeve channel 152 canhelp reduce binding or build-up of extrudable material 140 in sleevechannel 152 as extrudable material 140 advances through sleeve 126.

Referring generally to, e.g., FIG. 1 and particularly to FIGS. 10-13 ,at least one of plurality of grooves 162 intersects at least another oneof plurality of grooves 162. The preceding subject matter of thisparagraph characterizes example 22 of the present disclosure, whereinexample 22 also includes the subject matter according to example 20,above.

Having at least one of plurality of grooves 162 intersect at leastanother one of plurality of grooves 162 promotes flexibility in sleeve126 and allows more adjustability of the size and/or the shape of sleeveoutlet 132.

Referring to FIG. 11 , in one example, some of plurality of grooves 162oblique to flow direction 184 intersect some of plurality of grooves 162parallel to flow direction 184. Referring to FIG. 12 , in one example,only plurality of grooves 162, oblique to flow direction 184, intersecteach other.

Referring generally to, e.g., FIG. 1 and particularly to FIGS. 8-11 and13 , extrudable material 140 advances through sleeve 126 in flowdirection 184. At least some of plurality of grooves 162 are parallel toflow direction 184 of extrudable material 140. The preceding subjectmatter of this paragraph characterizes example 23 of the presentdisclosure, wherein example 23 also includes the subject matteraccording to any one of examples 20 to 22, above.

Plurality of grooves 162 provides an axis, about which adjacent ones ofplurality of sleeve segments 160 are pivotable relative to each other.Moreover, each one of plurality of grooves 162, being parallel to flowdirection 184 of extrudable material 140, provides an axis that is alsoparallel to flow direction 184 of extrudable material 140. The axes,being parallel to flow direction 184 of extrudable material 140,facilitates movement of plurality of grooves 162 toward and away fromcentral axis 194 in directions perpendicular to flow direction 184 ofextrudable material 140 to change the size and/or the shape of sleeveoutlet 132.

Referring generally to, e.g., FIG. 1 and particularly to FIGS. 10 and 13, extrudable material 140 advances through sleeve 126 in flow direction184. At least some of plurality of grooves 162 are perpendicular to flowdirection 184 of extrudable material 140. The preceding subject matterof this paragraph characterizes example 24 of the present disclosure,wherein example 24 also includes the subject matter according to any oneof examples 20 to 23, above.

One of plurality of grooves 162, being perpendicular to flow direction184 of extrudable material 140, provides an axis that is alsoperpendicular to flow direction 184 of extrudable material 140. Theaxis, being perpendicular to flow direction 184, facilitates thenecessary flexibility away from sleeve outlet 132 to accommodatemovement of sleeve outlet 132 toward and away from central axis 194 indirections perpendicular to flow direction 184 to change the size and/orthe shape of sleeve outlet 132.

Referring generally to, e.g., FIG. 1 and particularly to FIGS. 11-13 ,extrudable material 140 advances through sleeve 126 in flow direction184. At least some of plurality of grooves 162 are oblique to flowdirection 184 of extrudable material 140. The preceding subject matterof this paragraph characterizes example 25 of the present disclosure,wherein example 25 also includes the subject matter according to any oneof examples 20 to 24, above.

Plurality of grooves 162, being oblique to flow direction 184, providesan axis that is also oblique to flow direction 184. The axis, beingoblique to flow direction 184, facilitates movement of a portion ofsleeve outlet 132 in directions perpendicular to flow direction 184, butoffset from central axis 194, to change the size and/or the shape ofsleeve outlet 132. Generally, plurality of grooves 162, being oblique toflow direction 184, promotes greater flexibility and furthercustomization of the size and/or the shape of sleeve outlet 132.

Referring generally to, e.g., FIGS. 1-15 and particularly to FIG. 16 ,method 200 of shaping extrudable material 140 is disclosed. Method 200comprises (block 202) advancing extrudable material 140 through sleeve126 that comprises second sleeve end 188 and sleeve outlet 132 at secondsleeve end 188. Method 200 further comprises (block 204) selectivelychanging at least one of a size or a shape of sleeve outlet 132. Thepreceding subject matter of this paragraph characterizes example 26 ofthe present disclosure.

The ability to selectively change the size and/or the shape of sleeveoutlet 132 facilitates adjustment of the size and/or shape of extrudablematerial 140 delivered from a single apparatus, such as apparatus 110,which promotes the formation of self-supporting, out-of-plane structuresusing additive manufacturing methods without the need to substitute onenozzle for another. In other words, selective changing of the sizeand/or the shape of sleeve outlet 132 facilitates on-the-fly changes tothe size and/or the shape of extrudable material 140 extruded fromsleeve outlet 132 in an additive manufacturing process. Additionally,selectively changing at least one of the size or the shape of sleeveoutlet 132 allows additive manufacturing processes to form parts withhigher material throughput, reduced material usage, improvedinterlaminar adhesion, faster print speeds, better part geometry, bettersurface control, and reduced post-processing steps. Furthermore, sleeve126, being both flexible and non-stretchable, promotes changes to thesize and/or the shape of extrudable material 140, while not allowing thepressure of extrudable material 140 to deform sleeve 126, whichfacilitates predictable and controllable flow rates of extrudablematerial 140 from sleeve 126.

Referring generally to, e.g., FIGS. 1-9, 14, and 15 and particularly toFIG. 16 , according to method 200, selectively changing at least one ofthe size or the shape of sleeve outlet 132 comprises (block 206)selectively operating plurality of actuators 122, coupled to secondsleeve end 188 of sleeve 126 via plurality of cables 128. The precedingsubject matter of this paragraph characterizes example 27 of the presentdisclosure, wherein example 27 also includes the subject matteraccording to example 26, above.

Selectively operating plurality of actuators 122 promotes automatedchanging of at least one of the size or the shape of sleeve outlet 132.Furthermore, selectively operating plurality of actuators 122facilitates precise and predictable control of at least one of the sizeor the shape of sleeve outlet 132.

Referring generally to, e.g., FIGS. 1-9, 14, and 15 and particularly toFIG. 16 , according to method 200, selectively operating plurality ofactuators 122 comprises (block 208) pushing or pulling plurality ofcables 128. The preceding subject matter of this paragraph characterizesexample 28 of the present disclosure, wherein example 28 also includesthe subject matter according to example 27, above.

Pushing or pulling plurality of cables 128 promotes a simple andreliable actuation method for changing at least one of the size or theshape of sleeve outlet 132.

Referring generally to, e.g., FIGS. 1-9, 14, and 15 and particularly toFIG. 16 , according to method 200, extrudable material 140 advancesthrough sleeve 126 in flow direction 184. Pushing plurality of cables128 comprises (block 210) pushing plurality of cables 128 in firstdirection 190, perpendicular to flow direction 184 and toward centralaxis 194 of sleeve channel 152, defined by sleeve 126, to movecorresponding portions of second sleeve end 188 of sleeve 126 in firstdirection 190. Pulling plurality of cables 128 comprises (block 212)pulling plurality of cables 128 in second direction 192, perpendicularto flow direction 184 and away from central axis 194 of sleeve channel152, to move the corresponding portions of second sleeve end 188 ofsleeve 126 in second direction 192. The preceding subject matter of thisparagraph characterizes example 29 of the present disclosure, whereinexample 29 also includes the subject matter according to example 28,above.

Pushing plurality of cables 128 in first direction 190 and pullingplurality of cables 128 in second direction 192 promote movement, e.g.flexing, of at least a portion of sleeve outlet 132 in directionperpendicular to flow direction 184, which facilitates a change in atleast one of the size or the shape of sleeve outlet 132.

Referring generally to, e.g., FIGS. 1 and 8-13 and particularly to FIG.16 , according to method 200, sleeve 126 comprises plurality of grooves162 and plurality of sleeve segments 160. Adjacent ones of plurality ofsleeve segments 160 are pivotally coupled together by a correspondingone of plurality of grooves 162. Selectively changing at least one ofthe size or the shape of sleeve outlet 132 comprises (block 214) bendingsleeve 126 along at least one of plurality of grooves 162 to pivotadjacent ones of plurality of sleeve segments 160, pivotally coupledtogether by at least the one of plurality of grooves 162, relative toeach other. The preceding subject matter of this paragraph characterizesexample 30 of the present disclosure, wherein example 30 also includesthe subject matter according to example 28 or 29, above.

Bending sleeve 126 along plurality of grooves 162 to move plurality ofsleeve segments 160 relative to each other promotes a change to the sizeand/or the shape of sleeve outlet 132 while providing a strong frameworkfor resisting deformation due to the pressure of extrudable material 140as extrudable material 140 flows through sleeve 12.

Referring generally to, e.g., FIGS. 1, 3-7, and 15 and particularly toFIG. 16 , according to method 200, selectively changing at least one ofthe size or the shape of sleeve outlet 132 comprises (block 216)changing a size or a shape of shaping ring 130, surrounding and coupledto second sleeve end 188 of sleeve 126. Shaping ring 130 is more rigidthan second sleeve end 188 of sleeve 126. The preceding subject matterof this paragraph characterizes example 31 of the present disclosure,wherein example 31 also includes the subject matter according to any oneof examples 26 to 30, above.

Changing a size or a shape of shaping ring 130 facilitates a change ofthe size and/or the shape of sleeve outlet 132 by providing a rigid, yetrearrangeable, framework to sleeve outlet 132.

Referring generally to, e.g., FIGS. 1, 3-7, and 15 and particularly toFIG. 16 , according to method 200, shaping ring 130 comprises at leastfour links 134, each pivotally coupled to two adjacent ones of at leastfour links 134. Changing the size or the shape of shaping ring 130comprises (block 218) pivoting one of at least four links 134 relativeto another one of at least four links 134. The preceding subject matterof this paragraph characterizes example 32 of the present disclosure,wherein example 32 also includes the subject matter according to example31, above.

Pivoting links, such as at least four links 134, relative to each otherenables a simple and reliable actuation method for changing at least oneof the size or the shape of sleeve outlet 132.

Referring generally to, e.g., FIGS. 1-15 and particularly to FIG. 16 ,method 200 further comprises (block 222) advancing extrudable material140 through sleeve 126 while at least the one of the size or the shapeof sleeve outlet 132 is selectively changed. The preceding subjectmatter of this paragraph characterizes example 33 of the presentdisclosure, wherein example 33 also includes the subject matteraccording to any one of examples 26 to 32, above.

Selectively changing the size and/or the shape of sleeve outlet 132while advancing extrudable material 140 through sleeve 126 facilitateson-the-fly changes to the size and/or the shape of extrudable material140 extruded from sleeve outlet 132 in an additive manufacturingprocess.

Referring generally to, e.g., FIG. 1 and particularly to FIG. 16 ,method 200 further comprises (block 224) automatically selectivelychanging at least the one of the size or the shape of sleeve outlet 132using controller 102. The preceding subject matter of this paragraphcharacterizes example 34 of the present disclosure, wherein example 34also includes the subject matter according to any one of examples 26 to33, above.

Automatically selectively changing the size and/or the shape of sleeveoutlet 132 using controller 102 facilitates precise and predictablecontrol of at least one of the size or the shape of sleeve outlet 132.Also, using controller 102 to automatically selectively change the sizeand/or the shape of sleeve outlet 132 facilitates the use ofnumerically-controlled machines and associated software to execute anadditive manufacturing process.

Referring generally to, e.g., FIGS. 1-15 and particularly to FIG. 16 ,according to method 200, selectively changing at least the one of thesize or the shape of sleeve outlet 132 comprises (block 220) flexingsleeve outlet 132. The preceding subject matter of this paragraphcharacterizes example 35 of the present disclosure, wherein example 35also includes the subject matter according to any one of examples 26 to34, above.

Flexing sleeve outlet 132 to change the size and/or the shape of sleeveoutlet 132 provides a reliable and repeatable method for changing thesize and/or the shape of extrudable material 140 when forming a partusing an additive manufacturing process.

Examples of the present disclosure may be described in the context ofaircraft manufacturing and service method 1100 as shown in FIG. 20 andaircraft 1102 as shown in FIG. 21 . During pre-production, illustrativemethod 1100 may include specification and design (block 1104) ofaircraft 1102 and material procurement (block 1106. During production,component and subassembly manufacturing (block 1108) and systemintegration (block 1110) of aircraft 1102 may take place. Thereafter,aircraft 1102 may go through certification and delivery (block 1112 tobe placed in service (block 1114). While in service, aircraft 1102 maybe scheduled for routine maintenance and service (block 1116). Routinemaintenance and service may include modification, reconfiguration,refurbishment, etc. of one or more systems of aircraft 1102.

Each of the processes of illustrative method 1100 may be performed orcarried out by a system integrator, a third party, and/or an operator(e.g., a customer). For the purposes of this description, a systemintegrator may include, without limitation, any number of aircraftmanufacturers and major-system subcontractors; a third party mayinclude, without limitation, any number of vendors, subcontractors, andsuppliers; and an operator may be an airline, leasing company, militaryentity, service organization, and so on.

As shown in FIG. 21 , aircraft 1102 produced by illustrative method 1100may include airframe 1118 with a plurality of high-level systems 1120and interior 1122. Examples of high-level systems 1120 include one ormore of propulsion system 1124, electrical system 1126, hydraulic system1128, and environmental system 1130. Any number of other systems may beincluded. Although an aerospace example is shown, the principlesdisclosed herein may be applied to other industries, such as theautomotive industry. Accordingly, in addition to aircraft 1102, theprinciples disclosed herein may apply to other vehicles, e.g., landvehicles, marine vehicles, space vehicles, etc.

Apparatus(es) and method(s) shown or described herein may be employedduring any one or more of the stages of the manufacturing and servicemethod 1100. For example, components or subassemblies corresponding tocomponent and subassembly manufacturing (block 1108 may be fabricated ormanufactured in a manner similar to components or subassemblies producedwhile aircraft 1102 is in service (block 1114. Also, one or moreexamples of the apparatus(es), method(s), or combination thereof may beutilized during production stages 1108 and 1110, for example, bysubstantially expediting assembly of or reducing the cost of aircraft1102. Similarly, one or more examples of the apparatus or methodrealizations, or a combination thereof, may be utilized, for example andwithout limitation, while aircraft 1102 is in service (block 1114 and/orduring maintenance and service (block 1116).

Different examples of the apparatus(es) and method(s) disclosed hereininclude a variety of components, features, and functionalities. Itshould be understood that the various examples of the apparatus(es) andmethod(s) disclosed herein may include any of the components, features,and functionalities of any of the other examples of the apparatus(es)and method(s) disclosed herein in any combination, and all of suchpossibilities are intended to be within the scope of the presentdisclosure.

Many modifications of examples set forth herein will come to mind to oneskilled in the art to which the present disclosure pertains having thebenefit of the teachings presented in the foregoing descriptions and theassociated drawings.

Therefore, it is to be understood that the present disclosure is not tobe limited to the specific examples illustrated and that modificationsand other examples are intended to be included within the scope of theappended claims. Moreover, although the foregoing description and theassociated drawings describe examples of the present disclosure in thecontext of certain illustrative combinations of elements and/orfunctions, it should be appreciated that different combinations ofelements and/or functions may be provided by alternative implementationswithout departing from the scope of the appended claims. Accordingly,parenthetical reference numerals in the appended claims are presentedfor illustrative purposes only and are not intended to limit the scopeof the claimed subject matter to the specific examples provided in thepresent disclosure.

What is claimed is:
 1. A method of shaping an extrudable material, themethod comprising steps of: advancing the extrudable material through asleeve that comprises a first sleeve end and a second sleeve end,opposite the first sleeve end, and a sleeve outlet at the second sleeveend; and selectively changing at least one of a size or a shape of thesleeve outlet by changing a size or a shape of a shaping ring,surrounding and coupled to the second sleeve end of the sleeve, whereinthe shaping ring is more rigid than the second sleeve end of the sleeve.2. The method according to claim 1, wherein the step of selectivelychanging at least one of the size or the shape of the sleeve outletcomprises a step of selectively operating a plurality of actuators,coupled to the second sleeve end of the sleeve via a plurality ofcables.
 3. The method according to claim 2, wherein the step ofselectively operating the plurality of actuators comprises a step ofpushing or pulling the plurality of cables.
 4. The method according toclaim 3, wherein: the extrudable material advances through the sleeve ina flow direction; the step of pushing the plurality of cables comprisespushing the plurality of cables in a first direction perpendicular tothe flow direction and toward a central axis of a sleeve channel,defined by the sleeve, to move corresponding portions of the secondsleeve end of the sleeve in the first direction and the step of pullingthe plurality of cables comprises pulling the plurality of cables in asecond direction perpendicular to the flow direction and away from thecentral axis of the sleeve channel, to move the corresponding portionsof the second sleeve end of the sleeve in the second direction.
 5. Themethod according to claim 3, wherein the step of selectively operatingthe plurality of actuators comprises pushing a first one of theplurality of cables, relative to a sleeve inlet, and pulling a secondone of the plurality of cables, relative to the sleeve inlet.
 6. Themethod according to claim 3, wherein the step of pushing or pulling theplurality of cables comprises pushing or pulling the plurality of cableswithout stretching the plurality of cables.
 7. The method according toclaim 2, wherein the step of selectively operating the plurality ofactuators, coupled to the second sleeve end of the sleeve via theplurality of cables comprises moving each one of the plurality of cablesthrough a corresponding one of a plurality of cable tubes.
 8. The methodaccording to claim 1, wherein: the shaping ring comprises at least fourlinks, each pivotally coupled to two adjacent ones of at least the fourlinks; and the step of changing the size or the shape of the shapingring comprises pivoting one of at least the four links relative toanother one of at least the four links.
 9. The method according to claim1, further comprising a step of advancing the extrudable materialthrough the sleeve while at least the one of the size or the shape ofthe sleeve outlet is selectively changed.
 10. The method according toclaim 1, further comprising automatically selectively changing at leastthe one of the size or the shape of the sleeve outlet using acontroller.
 11. The method according to claim 1, wherein the step ofselectively changing at least the one of the size or the shape of thesleeve outlet comprises flexing the sleeve outlet.
 12. The methodaccording to claim 11, wherein the step of selectively changing at leastthe one of the size or the shape of the sleeve outlet comprises flexing,but not stretching, the sleeve outlet.
 13. The method according to claim1, wherein the step of selectively changing the shape of the sleeveoutlet comprises selectively changing the shape of the sleeve outletinto a square.
 14. The method according to claim 1, wherein the step ofselectively changing the shape of the sleeve outlet comprisesselectively changing the shape of the sleeve outlet into a polygon,comprising more than four sides.
 15. The method according to claim 1,wherein the step of selectively changing the shape of the sleeve outletcomprises selectively changing the shape of the sleeve outlet into anasymmetrical shape.
 16. The method according to claim 1, wherein: theshaping ring comprises at least eight links, each pivotally coupled totwo adjacent ones of at least the eight links; and the step of changingthe size or the shape of the shaping ring comprises pivoting one of atleast the eight links relative to another one of at least the eightlinks.
 17. The method according to claim 1, further comprising extrudingthe extrudable material having the size and the shape of the sleeveoutlet, from the sleeve outlet in an additive manufacturing process. 18.The method according to claim 17, further comprising automaticallyselectively changing at least the one of the size or the shape of thesleeve outlet using a controller, wherein the additive manufacturingprocess is executed using at least one numerically-controlled machine.19. A method of shaping an extrudable material, the method comprisingsteps of: advancing the extrudable material through a sleeve thatcomprises a first sleeve end and a second sleeve end, opposite the firstsleeve end, and a sleeve outlet at the second sleeve end; andselectively operating a plurality of actuators, coupled to the secondsleeve end of the sleeve via a plurality of cables to selectively changeat least one of a size or a shape of the sleeve outlet wherein: each oneof the plurality of cables passes through a corresponding one of aplurality of cable tubes; the plurality of cable tubes are fixed to asupport structure; the support structure is more rigid than the sleeve;and the step of selectively operating the plurality of actuatorscomprises moving each one of the plurality of cables through thecorresponding one of the plurality of cable tubes.
 20. The methodaccording to claim 19, wherein: the sleeve comprises: a plurality ofgrooves; and a plurality of sleeve segments, wherein adjacent ones ofthe plurality of sleeve segments are pivotally coupled together by acorresponding one of the plurality of grooves; and the step ofselectively changing at least one of the size or the shape of the sleeveoutlet comprises bending the sleeve along at least one of the pluralityof grooves to pivot adjacent ones of the plurality of sleeve segments,pivotally coupled together by at least the one of the plurality ofgrooves, relative to each other.